Method of manufacturing flux carrying rods or wire



C. J. KOTCHI Oct. 9, 1934.

METHOD OF MANUFACTURING FLUX CARRYING RODS OR WIRE.

Original Filed 0a. 31. 1927 4 Shoeis-Shget .1

arweg,

O 1934- c. J. KOTCHI METHZJD OF MANUFACTURING FLUX CARRYING RODS 0R WIREOriginal Filed Oct. 1, 1927 4 Sheets-sheaf. 2

0 Oct. 9, 1934. c, J. KOTCHl 1,976,026

METHOD OF MANUFACTURING FLUX CARRYING RODS OR WIRE Original Filed Oct.51, 1927 4 Sheets-Sheet 3 orne}.

Oct. 9, 1534. J OT H, 1,976,026

METHOD OF MANUFACTURING FLUX CARRYING RODS OR WIRE Original Filed 09%;.51, 1927 4 Sheets-Sheet I 4 Patented Oct. 9, 1934 METHOD OF MANUFACTURINCARRYING RODS R WIRE G FLUX Charles J., Kotchi, Chicago, 111., assignor,by

mesne assignments, to

Una Welding Inc., Cleveland,'0hio, a corporation of Delaware Original229,851, now

tion January 18, 1929,

6 Claims.

This application is a division of original application Serial Number229,851, filed October 31, 1927, since matured into Patent No. 1,702,304dated February 19, 1929, and one of the objects of the present inventionis to provide an improved method for manufacturing rods or wire forwelding purposes and the like, and in which rod or wire is incorporateda flux so that as the rod or wire is used and consumed flux inpredetermined quantities will be automatically supplied to the work, therod or wire and flux dropping ofif in the form of pellets, whereby acontinuous operation may be performed by the use of such rod or wire andthe necessity of stopping the work or withdrawing the rod or wire fromthe puddle to supply a quantity of fiux will be obviated.

A further object is to provide an improved method for supplying the fluxto the rod or wire and for packing the flux in the cavities or recessesin the rod.

To the attainment of these ends and the accomplishment of other new anduseful objects as will appear, the invention consists in substantiallythe method hereinafter more fully described and claimed, in connectionwith the accompanying drawings.

This method may be carried into operation by any suitable mechanism ormachine but in order that the method may be fully understood, there isshown and described one form of machine which is adapted for carryingthe invention into operation.

In the drawings:

Figure 1 is a vertical longitudinal sectional view of a machine of 'thischaracter constructed in accordance with the principles of thisinvention.

Figure 2 is a top plan view of Figure 1.

Figure 3 is a right hand end elevation of Figure 1. a

Figure 4 is an enlarged detail vertical sectional view taken on line4-4, Figure 1.

Figure 5 is a vertical sectional view taken on line 5-5, Figure 2.

Figure 6 is a sectional view taken on line 6-6, Figure 5.

Figure 7 is a view taken on line 7-7, Figure 8, with parts broken awa;and parts in section.

Figure 8 is a view taken on line 8-8, Figure 7.

Figure 9 is an enlarged detail sectional view of application October 31,

Patent No. February 19, 1929. Divided 1927, Serial No.

1,702,304, dated and this applica- Serial No. 333,319

a portion of the knurling wheels and showing the manner in which the rodis knurled and supported.

Figure 10 is a detail sectional view taken on line 10-10, Figure 9.

Figure 11' is an enlarged detail sectional view showing the manner inwhich the knurled rod is guided through the flux tank and the means.whereby the flux is packed within the cavities or recesses in the rod.

Figure 12 is a detail of the completed rod.

In the machine shown in the drawings which particularly adapted forcarrying the present vention into operation, the numeral 15 designates asupport of any suitable character upon which are mounted suitablebearings for rotatably supporting knurling wheels 16-17. These wheelsare respectively provided with spaced teeth 18-19 and between whichwheels the rod or 7 material 20 is passed. The wheels 16-17 are disposedone above the other. One of the wheels, preferably the upper wheel,rotates freely and the lower wheel 17- is preferably driven through themedium of intermeshing gears 21-22, one of which is connected with thewheel 17 and the other to an upright shaft 23, the shaft 23 beingjournaled in a suitable bearing 24. The shaft 23 is driven by suitableintermeshing gears 25-28, the gear 26 being connected to a shaft 27which 30 is journaled in suitable bearings 28. The shaft 27 is drivenfrom a shaft 27 on which a gear 2'7 is secured for rotation therewithand this gear 27 meshes with a gear 27 which is turn is secured to theshaft 2'7. The shaft 27 is journaled in suitable bearings 27-27% I Theshaft 27 is driven by means of a gear 29 which meshes with a gear 30,the latter being connected with a shaft 31 that is driven from a motor32 preferably mounted upon a base 33, the shaft 31 being journaled insuitable bearings 34-35.

A guide 36 is provided in alinement with the bite of the indenting orrecessing wheels 16-17 and through which guide 36 the wire or rod 20passes. Another guide 37 is arranged on opposite sides of the wheels16-17 and the forward extremity of the guide 37 extends for aconsiderable distance into the bite of the wheels 16-17 as at 38 (seeparticularly Figure 9), so as to sup- 60 top plan view of a portion thesupport 15 by means of another support '41 whereby a burner or heater 42which receives its supply of fuel through a pipe 43, may be disposedbeneath the tank 40 so as to keep the contents of the tank warm. Thetank 40 is disposed within and spaced from an outer tank 44 to form aliquid space 45 between the tanks, and the end 39 of the guide 3'7projects through both of the tanks and into the innermost tank 40,suitable packing 46 being provided to form a liquid tight joint.

Within the tank 40 is a fiux 4'7. 1

An additional guide 48 is supported bythe walls of the tank 40-44,suitable packing material 49 being provided to form a fluid tight joint.The extremity 50 (see particularly Figure 11) of the guide 48 projectsinto the tank 40 and termi nates in close proximity to the extremity 39of the guide 3'7, but terminates short therefrom so as to' permit theflux 4'7 in the tank or container 40 to be disposed between theextremities 39 and 50 of the respective guides 3'7 and 48 to fill therod or work 20 as it passes through the tank'40.'

The end 50 of the guide 48 within the tank 40 is concaved or recessed asat 51, the walls of the recess or cavity converging from the extremity50 of the guide inwardly and toward the diametric center thereof.

As the rod or work 20 passes between the rolls 16 and 17 the teeth 18and 19 co-operating will operate upon the rod to form cavities 52therein, and these cavities are formed by an extruding process, theteeth 18 and 19 being so shaped and arranged as to provide cavitieswhich are out of communication with each other.

With this'method of producing the cavities in the rod the portion of thematerial of the rod between adjacent cavities will be compressed orcrystallized, with the result that during the consumption of the rod inuse, the am will form a crater or cavity in the end of the rod, with thefurther result that the spit and sputter usually present when weldingrods are used, will be obviated.

Further, this construction of rod renders it possible to more readilycontrol the arc and enable the operator to localize the same. v

As the rod with the cavities or recesses 52 therein passes out of theguide 3'7, through the tank 40 and into the guide 48 the flux 4'7 in thetank 40 will enter the cavities 52 in the rod. The rod as it advanceswill cause the flux to advance with it'and the inclined or taperedsurface 51 of the cavity in the end of the guide 48 serves as a meansfor compacting and pressing the flux into the cavities 52, therebyinsuring that the cavities will be filled. v

Arranged adjacent the support 15 is a standard 7 or frame 53 havingspaced bearings 54 at the top thereof in which a straightening head 55is rotatably mounted by journaling the ends 56 of the head in thebearings 54. The .straightener 55 and the ends 56 are provided with anopening therethrough in alinement with the opening of the guide 48 sothat as the wire leaves the guide 48 it will pass into the opening inthe head 55. Oppositely disposed pairs of screws 5'7 are adjustablymounted in the straightener 55 and the proximate same forwardly.

extremities of adjacent screws 5'7 are arranged in alinement and contactwith the rod or work 20 for straightening the rod as it passes throughthe straightener 55. These screws 5'7 may be adjusted as desired and theends of the screws also serve as a means for removing or scraping fromthe rod 20 any excess flux.

The straightener 55 is axially rotated preferably from the shaft 31through the medium of a pulley 58 secured with the shaft 31 for rotationtherewith and a pulley 59 secured to the straightener 55, a belt 60passing over the pulleys 58 and 59.

Supported preferably by the standard or frame 53 and rotatable uponvertical axes are feeding rollers 61-62. The rollers are providedrespectively with grooves 63-64 in their peripheries and the rod or work20 passing into the bite of these rollers will enter the grooves 63 and64, the rollers 61 and 62 frictionally binding upon the work or rod andoperating to draw or feed'the The rollers 61-62 are respectively mountedin adjustable bearings 65-66 whereby they may be adjusted to compensatevarying diameters of the work.

The roller 62 rotates freely while the roller 61 is preferablypositively driven. To that end the shaft 67 of the roller 63 is mountedin a ball bearing 68 and secured to the shaft 6'7 is a gear 69. Mountedupon a shaft '70 is a gear '71 which meshes with the gear 69 and thegear '71 is adapted to be freely adjusted upon the shaft '70 in adirection lengthwise of the axis of the shaft, in any suitable manner,preferably by means of a pin or key '72 which slides in a keyway '73 inthe shaft '70.

An adjusting screw '74 provided with an adjusting head '75 and a locknut '76- is provided and is rotatably supported in suitable bearings.Carried by the screw '74 is a collar '77 having a projection 78 whichenters a groove '79 in the hub of the ear 71.

By adjusting the screw '74 the gear '71 may be adjusted lengthwise ofthe shaft '70 so that another gear of difierent diameter may besubstituted for the gear 69. The roller 61 is adjustable by means of ascrew '80 and the gear 62. is adjustable by means of a screw 81.

Motion is imparted to the shaft '70 by means of a gear 82 securedthereto which meshes with a gear 83 secured to a shaft 84 that isjournaled in suitable bearings 85-86. Connected also with the shaft 84for rotation therewith is a gear 8'7 that meshes with a gear 88, whichin turn is secured to the shaft 2'7 for rotation therewith. Thus it willbe seen that the indenting or recessing rolls 16 and 1'7, thestraightener head 55 and the feeding rolls 61 will all be operated fromthe shafts 37 and 31 and in unison.

As the rod orvwork passes from between the rolls 61 and 62 it will passthrough a cutter member 89 with which a cutter 90 mounted upon a lever91 co'-operates for severing the wire or rod into predetermined lengths,and when severed the lengths may drop upon a suitable support asindicated at 92. The cutting element 90 is adjustable upon the end ofthe lever 91 by means of suitable adjusting means 93 and the lever ispivotally mounted intermediate its ends as at 94 upon the frame orstandard 53. The cutting element 89 is removably held in position bymeans of a fastening device 95.

Loosely mounted upon the shaft 2'7 is acam element 96 and the end 9'7 ofthe lever 91 is disposed adjacent the path of movement of the cam 15096. The extremity 97 of the lever is preferably deflected as at 98 andan anti-friction roller 99 is journaled upon the deflected portion to beengaged by the cam 96 under predetermined conditions to rock the lever97 in one direction and thereby effect a severing of the rod or workinto predetermined lengths, the lever 91 being returned preferably bymeans of a suitable spring 97', and against the stress of which springthe cam 96 rocks the lever.

Connected also with the shaft 27 is a clutch member 100 provided with arecess 101 opening through one face thereof to receive a pin 102, whichlatter is carried with the cam-member 96 and for free movement laterallywith respect thereto. The pin 102 is provided with a flange 103, and aspring 104 tends normally to project the end of the pin 102 beyond thecam member 96 was to enter the recess 101 and thereby lock the cammember 96 through the medium of the clutch member 100 with the shaft 27'for rotation therewith. A vertical movable pin or member 105 is mountedto slide loosely in a guide 106 and this pin or member 105 is adapted ata predetermined time in the cycle of operation of the machine, to assumea position to be engaged by the cam shaped flange 103 (see Figure '7) towithdraw the pin 102 from the clutch member 100 and thereby release thecam member 96 with respect to the shaft 27-. When this operation iseflected the lever 91 will remain idle.

A support 107 is pivotally mounted as at 108 adjacent the cam member 96.The support is provided with a slot 109 in which a bearing 110 carryinga gear 111 is adjustably mounted. This gear 111 meshes with a gear 112carried by the shaft 27. Carried by the gear 111 is an arm 113 which isadapted to engage a shoulder 114 v on a member 115 that is secured tothe member or pin 105 so that when the gear 111 is rotated underpredetermined conditions the arm 113 will engage the projection 114 thatis connected with the pin 105 to raise the latter out of engagement withthe flange 103 of the pin 102 thereby allowing the spring 104 to projectthe pin 102 into the recess 101 for locking the cam 96 for rotation withthe shaft 27 to rock the lever 91.

As soon as the arm 113 passes out of engagement with the shoulder 114 onthe member 105, the latter will drop and a beveled surface 116 (seeFigure 7) on the member 105 will engage the beveled surface on theflange 103 and thereby withdraw the pin 102 from the recess 101 in theclutch member 100, thereby unlocking the cam with respect to the shaft27.

The oscillation of the lever 91 in this manner will sever the rod 20into predetermined lengths and the lengths of the portions severed aregoverned by the diameter of the gear 101.

By removing the gear 111 and substituting therefor another gear of adifferent diameter a different length portion will be severed from therod. The interchanging of gears may be readily effected as the slot 109in the support 107 will permit gears of different diameters to besupported thereby and by swinging the support 107 about its pivot 108through the medium of the handle 117 the varying sizes in theinterchanged gears 101 may be compensated.

The support 107 may be held in its adjusted position by means of asuitable fastening device 118 passing through a slot 119 and eng ing asuitable support.

Connected with the cam member 96 is a brake wheel 120 with which a handbrake 121 co-operates to prevent overthrow of the parts.

If desired a fly or balance wheel 122 may be connected with the clutchmember 100.

Suitable scrapers 123 (see Figure 2) may be provided, if desired, formaintaining the peripheries of the wheels 61 and 62 free from fluxingmaterial.

With this improved method it will be manifest that there will beprovided a continuous operation in the manufacture of the rod or wire,as the rod or wire when inserted into one end of the machinewill,'through its course through themachine, be shaped or recessed toproduce the desired cavities, the cavities will be fllled with flux andthe flux compacted therein, the wire or rod will be straightened and theexcess flux will be scraped therefrom and flnally the rod will besevered into sections of predetermined lengths.

With this improved method the cavities will be formed in the rod or wireby extruding the metal thereof to compress the material between adjacentcavities, with the result that during the consumption of the rod or wirea crater will be formed in the end of the rod which localizes the arcand gives the operator a better control and a penetration by the are.This is due to the compressing and crystallization of certain portionsof the rod.

1 While the preferred method of producing the rod or wire has beenherein described, it is to be understood that various changes may bemade in thedetails and in the steps of ca ying this method intooperation, within the scope of the claims, without departing from thespirit of this invention.

What is claimed as new is:-

1. The method of manufacturing flux carrying welding rods which consistsin forming in the rod open and disconnected cavities and compressing thematerial of the rod between adjacent cavities, then passing the rodthrough a quantity of flux to flll the cavities, and then scraping offthe surplus flux from the portion of the rod between the cavities.

2. The method of manufacturing flux carrying rods or wire which consistsin finally shaping the rod by forming cavities therein by extruding themetal thereof to compress the material between adjacent cavities, thensupplying flux in said cavities, and then removing the surplus flux fromthe rod to cause the rod between the cavities to be bare.

3. The method of manufacturing flux carrying I rods or wire whichconsists in finally shaping the rod by forming cavities therein, thenfilling and compacting flux in said cavities, and then removing surplusflux from the rod to cause the surface of the rod between the cavitiesto be bare.

4. The method of manufacturing flux carrying rods or wire which consistsin forming cavities in the rod, then passing the rod through a supply offlux to flll the cavities with flux, and

Ill

then removing surplus flux from the rod to cause the surface of the rodbetwen the cavities to be bare with exposed portions of flux betweensuch bare surfaces.

5. The method of manufacturing flux carrying rods or wire which consistsin forming cavities in the rod, then passing the rod through a supply offlux to fill the cavities with flux and compact the flux therein, andthen removing surplus flux from the rod to cause the surface of the rodbeuse of manufacturing flux carrying extruding the metal thereof toriphery of the rod and with the core intermediate adjacent cavities,then applying flux in said cavities, the flux in the finished productbeing substantially flush with the adjacent portion of the periphery ofthe rod, and then scraping off the surplus flux from the portion of theperiphery of the rod between the cavities.

CHARLES J. xo'rcm.

